Apparatus for refining metal carbides containing free carbon

ABSTRACT

Metal carbide powders containing free carbon which have heretofore been difficult to refine can be refined excellently by charging the metal carbide powders in a fluidizing bed consisting of fluidized heat-resistant particles and having a temperature of a determined range to burn and remove the free carbon contained therein, and by subsequently discharging refined metal carbide powders and combustion gas from an upper part of the fluidizing bed for recovery of the refined metal carbide powders.

This is a division of application Ser. No. 109,114 filed Jan. 2, 1980,now U.S. Pat. No. 4,327,067 issued Apr. 27, 1982.

BACKGROUND OF THE INVENTION

The present invention relates to a method and an apparatus for refiningmetal carbide containing free carbon, particularly to a method ofburning and removing free carbon contained in a fine metal carbidepowder such as powders of carbide of silicon, titanium, tantalum,niobium, tungsten, vanadium and the like and an apparatus used therefor.

Heretofore, metal carbide has been produced mainly by allowing carbon toreact with a metal or a metal oxide. In a metal carbide produced by sucha method, there are unavoidably mixed free carbon combined with themetal carbide. Therefore, a step of refining a metal carbide by removingfree carbon has become an important process in producing a metalcarbide.

For removing free carbon contained in a metal carbide, there havehitherto been known methods such as (a) gravity concentration methodusing the difference between specific gravities of a metal carbide andfree carbon, (b) floatation method using the difference betweenaffinities to air of a metal carbide and free carbon, and (c) burningmethod of removing free carbon using the difference between oxidationspeeds of a metal carbide and free carbon. Among these methods, thegravity concentration method (a) has a disadvantage of requiring aprolonged time for separation unless the metal carbide has relativelycoarse particles and the gravity difference is large. While, thefloatation method (b) has been disclosed, for example, in JapanesePatent Application Publication No. 24,480/76, it has a disadvantage thatthe efficiency of separation decreases unless particle sizes of metalcarbide to be treated are set in a relatively narrow range. Moreover,either the method (a) or (b) has a disadvantage that metal carbide andfree carbon have to be preliminarily separated to their unit particlesbefore being subjected to respective treatment. However, the burningmethod (c) of removing free carbon is capable of removing free carbonuniformly even when metal carbide to be treated is fine particles whichare difficult to be preliminarily separated to unit particles of metalcarbide and free carbon.

For the burning method of removing free carbon contained in a metalcarbide, there can be conceived such methods as (1) a method of burningthe free carbon contained in the metal carbide on a dish type containerin a furnace, (2) a method of burning the free carbon contained in themetal carbide in a multi-stage furnace or a revolving furnace such as arotary kiln and we conceived of (3) a method of burning the free carboncontained in the metal carbide under fluidization of the metal carbide.Among these methods, either the method (1) or (2) has drawbacks thatefficiency of contacting free carbon with an oxidizing gas is low sothat a prolonged time is necessary for burning and removing free carbonsufficiently, and that the loss of metal carbide due to oxidizationthereof is large. Therefore, both the methods (1) and (2) have not beensuitable methods for refining a great quantity of metal carbide.Meanwhile, we have found out that the method (3) of fluidizing metalcarbide has extremely high efficiency of contacting metal carbide withan oxidizing gas, however, it has drawbacks in that fine metal carbidepowders are liable to scatter unless the grain size of the metal carbidepowders is set in a coarse range and that a uniform fluidizing state isscarcely obtained because of formation of agglomerated masses of themetal carbide powders due to the adhering property of formed oxides atsurfaces of metal carbides during the burning process. Hence, it is notsuited particularly to burning and removing of free carbon contained infine metal carbide powders.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a method wherein theaforementioned disadvantages and drawbacks are essentially obviated oreliminated and fine metal carbide powders containing free carbon whichhave heretofore been difficult to refine by removing free carboncontained therein can be treated and refined in a large quantity with ahigh recovery efficiency in a short time without loss of metal carbidedue to its oxidation by burning the removing the free carbon containedtherein.

It is another object of the present invention to provide an apparatusfor use in the practice of the refining method.

In accordance with the present invention, the above objects can beachieved.

The present invention provides a method of refining metal carbidepowders containing free carbon which comprises, producing a fluidizingbed consisting of fluidized heat-resistant particles by means of anoxidizing gas, charging metal carbide powders finer than theheat-resistant particles from a lower part of the fluidizing bed,burning the free carbon during floating and rise of the metal carbidepowders in the fluidizing bed at a temperature of 800-1,100° C., andsubsequently scattering and discharging refined metal carbide powdersand combustion gas from an upper part of the fluidizing bed for recoveryof the refined metal carbide powders.

The present invention provides also an apparatus for refining metalcarbide powders containing free carbon, comprising a sealed vessel forproducing a fluidizing bed consisting of heat-resistant particles havingan average particle diameter of 150-500μ fluidized by an oxidizing gas,an inlet for introducing the oxidizing gas arranged at the lower end ofthe sealed vessel, a gas distributor for dispensing the oxidizing gas inthe fluidizing bed arranged at a lower part of the fluidizing bed, aninlet for charging the metal carbide powders located just above the gasdistributor, a heating member for heating the fluidizing bed arranged inthe refining apparatus to burn and remove the free carbon from the metalcarbide powders, an outlet for discharging a mixture of refined metalcarbide powders and combustion gas from the fluidizing bed arrangedabove the fluidizing bed, and a separator for recovering the refinedmetal carbide powders from the mixture discharged from the outlet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatical graph illustrating an embodiment of arefining apparatus of the present invention used in Examples 1 and 2which will later be described,

FIG. 2 is a diagrammatical longitudinal crosssection of a sealed vesselor column constituting a refining apparatus of the present inventionused in Example 3 which will also be described later, and

FIG. 3 is a diagrammatical graph illustrating an apparatus of afluidizing bed used in Comparative Example 3 which will also bedescribed later.

DETAILED EXPLANATION OF THE INVENTION

According to the present invention, metal carbides such as carbide ofsilicon, titanium, tantalum, niobium, tungsten, vanadium and the likecan be refined satisfactorily, because they are resistive to oxidationat high temperature and their losses due to oxidation during therefining operation are small. Especially, silicon carbide can be refinedadvantageously, because it has superior oxidationresistive property andloss due to oxidation is extremely small.

It is important in the present invention that the metal carbide is inthe form of sufficiently fine powders, because free carbon contained inmetal carbide is burned while the metal carbide powders containing itare moved from a lower position in an upward direction by means of anoxidizing gas in a heat-resistant or refractory sealed vessel retainedat a high temperature. Preferably, the average grain size of metalcarbide powders containing free carbon is not over than 200μ. Metalcarbide powders having an average grain size larger than 200μ aredifficult to float and move from a lower position to an upward positionby an oxidizing gas, so that they are difficult to be discharged fromthe upper part of the sealed vessel for recovery and thus theyaccumulate gradually in the sealed vessel, making continuous operationof the process difficult.

In the present invention, it is essential that a fluidizing bedconsisting of fluidized heat-resistant particles is formed in therefractory sealed vessel, so that free carbon contained in metal carbidepowders is burned during floating and moving of the metal carbidepowders with the aid of an oxidizing gas. By using a fluidizing bedconsisting of fluidized heat-resistant particles, metal carbide powderscontaining free carbon can have a substantially uniform residence timein the sealed vessel and are kept from agglomeration due to formation ofoxides at surface of the metal carbide powders in the sealed vessel.Therefore, the free carbon is efficiently contacted with the oxidizinggas, so that the free carbon contained in the metal carbide powders canbe burned and removed quite efficiently.

The heat-resistant particles are used in an oxidizing atmosphere of hightemperature range, so that they are preferably inorganic solid particleswhich do not melt and react with the metal carbide powders or theoxidizing gas. Illustrative of such particles are, for example, silica,alumina, mullite, magnesia, zirconia, zircon sand, silicon carbide andthe like.

An average particle size of the heat-resistant particles constitutingthe fluidizing bed is preferably within a range of 150-500μ. When theaverage particle size of the heat-resistant particles is less than 150μ,the heat-resistant particles are discharged along with the oxidizing gasrising in the fluidizing bed from an outlet at an upper part of thesealed vessel and incorporated in the discharged metal carbide powdersto lower the quality of the metal carbide powders. While, when theaverage particle size of the heat-resistant particles is over than 500μ,over-large bubbles are liable to be formed and a uniform fluidized statecannot be retained, so that the efficiency of contacting free carbonwith the oxidizing gas is decreased.

It is necessary that the metal carbide powders be finer than theheat-resistant particles, because the metal carbide powdes are floated,scattered and separated from the fluidizing bed consisting of thefluidized heat-resistant particles.

A bed height a minimum fluidizing gas velocity is preferably within arange of 0.2-3.0 m. When the bed height is less than 0.2 m, theresidence time of metal carbide powders in the fluidizing bed becomesuneven, so that incompletely or insufficiently burned free carbon isdischarged. While, when the bed height is larger than 3.0 m, a residencetime of the metal carbide powders in the fluidizing bed becomesunnecessarily long, so that consumption loss of metal carbide powdersdue to oxidation becomes large. Also, pressure loss of the oxidizing gasdue to the heat-resistant particles becomes extremely large and thepressure of the incoming oxidizing gas has to be increased to overcomethe pressure loss and hence the necessary blower-pressure capacity forintroducing the oxidizing gas becomes uneconomically large.

If bubbles in the fluidizing bed become coarse by agglomeration in thecase of burning free carbon in the fluidizing bed, the efficiency ofcontacting free carbon with the oxidizing gas decreases. Therefore, itis preferable to arrange in the fluidizing bed a bubble dispersingelement such as a cylindrical net of stainless steel wire.

In order to minimize the loss of metal carbide powders due to theoxidation and to burn free carbon efficiently, it is necessary that theburning operation be effected at a temperature range of 800-1,100° C,which is higher than a reaction temperature generally used in aconventional burning method of removing free carbon. When the burningtemperature or reaction temperature is lower than 800° C., thecombustion rate of free carbon is slowed down and some free carbon isleft unreacted, so that the efficiency of removing free carbon isdecreased. While, when the reaction temperature is higher than 1,100°C., the product metal carbide powders are oxidized extremely rapidly, sothat the loss of product becomes large and the quality of the product isalso deteriorated.

According to the present invention, the reaction temperature shouldpreferably be kept in the determined range for the reason mentionedabove, therefore, for that purpose, it is satisfactory to control atemperature of the fluidizing bed. When the quantity of free carboncontained in the metal carbide powders is so minor that the reactiontemperature of the fluidizing bed is scarcely maintained by merecombustion heat of the free carbon, an auxiliary heating member mayadditionally be used for heating the fluidizing bed. When controllingthe temperature of the fluidizing bed or applying heat to the fluidizingbed by the auxiliary heating member, desirably a method is used whereinincorporation of impurities into the metal carbide powders is suppressedto a minimum extent. For example, an electrical indirect heating method,a heating method of using a fuel substantially free from ash or a methodof preheating the oxidizing gas by a heat exchanger is advantageous.

In order to make the fluidizing bed burn and remove efficiently freecarbon contained in the metal carbide powders, it is advantageous to setthe superficial gas veolcity of the oxidizing gas at a determined range,preferably within a range of 5-100 cm/sec. When the superficial gasvelocity is less than 5 cm/sec, the amount of refined metal carbidepowders per unit of time is decreased, so that the refining efficiencyis decreased and a uniformly fluidized state of the heat-resistantparticles is hardly attained. The metal carbide powders are barelylifted by the oxidizing gas in the fluidizing bed and hardly dischargedfrom the outlet. Thus the metal carbide powders are accumulated in thefluidizing bed, thereby making the continuous operation of the processimpossible. While, when the superficial gas velocity is larger than 100cm/sec, the residence time of the metal carbide powders in thefluidizing bed becomes so small that the efficiency of removing freecarbon decreases. The heat-resistant particles are scattered anddischarged from the outlet by the oxidizing gas and introduced asimpurities into the product refined metal carbide powders therebylowering the quality of the refined product. Particularly, a superficialgas velocity of 10-40 cm/sec is preferable.

For an oxidizing gas, air can advantageously be used to oxidize andremove free carbon sufficiently. Alternatively, air enriched with oxygencan successfully be used, as the case may be.

Products of conventional fluidizing bed are generally discharged from alower part of the fluidizing bed, whereas, according to the presentinvention, the metal carbide powders are discharged together with thecombustion gas from an upper part of the fluidizing bed and recovered.This is because the burning reaction of free carbon is effected bycausing the extremely fine metal carbide powders and free carbon to riseby means of the oxidizing gas in the fluidizing bed consisting offluidized heat-resistant particles so that the metal carbide powdersexist in the rising combustion gas stream, and hence the metal carbidepowders are quite easily and efficiently separated and recovered fromthe heat-resistant particles by discharging a mixture of the metalcarbide powders and the combustion gas from an upper part of thefluidizing bed and subsequently separating the powders from the mixtureby a separator.

Once refined metal carbide powders can further be subjected to a similartreatment and/or the above gravitation method or floatation method tofurther remove free carbon for further refining the metal carbidepowders.

According to the apparatus of the present invention, metal carbidepowders containing free carbon are charged from the inlet for chargingmetal carbide powders arranged above the gas distributor in the sealedvessel. Free carbon contained in the metal carbide powders is burned andremoved during the rise of the metal carbide powders in the fluidizingbed consisting of the fluidized heat-resistant particles, and refinedmetal carbide powders are floated and scattered from the fluidizing bedand discharged together with the combustion gas from the outlet arrangedat an upper part of the fluidizing bed and then enter into the separatorfor recovery.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, the present invention will be explained in more detail withreference to the preferred embodiments shown in the appended drawings.

Referring to FIG. 1, the apparatus of the present invention is providedwith a fluidizing bed 1 consisting of fluidized heat-resistant particlesinside of a refractory sealed vessel 2, an inlet 3 for supplying anoxidizing gas located at the lower end of the sealed vessel 2, a gasdistributing plate 4 for dispensing the supplied oxidizing gas locatedat a lower part of the fluidizing bed 1, an inlet 5 for charging metalcarbide powders located near and above the gas distributing plate 4, anoutlet 6 for discharging a mixture of the burned or refined metalcarbide powders and the combustion gas located above the fluidizing bed1, and a collector 7 for recovering the product refined metal carbidepowders connected to the outlet means 6.

It is essential that the fluidizing bed 1 consists of fluidizedheat-resistant particles having an average particle diameter of150-500μ. When the average diameter of the heat-resistant particles isless than 150μ, the heat-resistant particles rise too high and areoverly scattered from the fluidizing bed 1 by the oxidizing gas anddischarged from the upper outlet 6 and incorporated into the productrefined metal carbide powders, deteriorating its quality. While, whenthe average diameter of the heat-resistant particles is more than 500μ,bubbles of the oxidizing gas are liable to become coarse byagglomeration in the fluidizing bed 1, so that a uniform fluidizingstate is difficult to produce.

A bed height at minimum fluidizing gas velocity of the fluidizedheat-resistant particles constituting the fluidized bed 1 is preferablywithin a range of 0.2-3.0 m. When the bed height of the fluidizedheat-resistant particles is less than 0.2 m, the residence time of themetal carbide powders in the fluidizing bed 1 becomes short and uneven,so that insufficiently burned free carbon is liable to be discharged.While, when the bed height is larger than 3.0 m, the residence time ofthe metal carbide powders in the fluidizing bed 1 becomes unnecessarilylong, so that the loss of metal carbide powders due to oxidation becomesintolerably large and the pressure loss of the oxidizing gas becomesextremely large. Thus the pressure of the introduced oxidizing gas hasto be increased in order to overcome the pressure loss, and hence therequired capacity of a blower 8 becomes uneconomically large.

The refractory sealed vessel 2 has in its interior the fluidizing bed 1consisting of the fluidized heat-resistant particles, so that the innerwall of the sealed vessel 2 suffers from severe abrasion of thefluidized heat-resistant particles. Therefore, it is advantageous toprepare the inner wall of the vessel 2 from a heat-resistant andabrasion-resistant material such as stainless steel or the like.

The gas distributing plate 4 for dispensing the supplied oxidizing gashas a function of uniformly distributing the oxidizing gas so as tofluidize the heat-resistant particles, and is preferably made of aheat-resistant and oxidation-resistive material such as a porous plateof stainless steel having uniformly spaced small holes, a porousrefractory material or the like. In order to obtain a uniformlyfluidized state, the gas distributing plate 4 has preferably small holeseach having a diameter of not over than 5 mm and an opening ratio ofcrosssectional area of small holes to a crosssectional area of thesealed vessel within the range of about 0.1-1.0%.

It is important that the inlet 5 for charging metal carbide powderscontaining free carbon be arranged at the lowest possible position ofthe fluidizing bed 1, and it is necessary that the inlet 5 be arrangednear above the gas distributing plate 4. This is because if the inlet 5is arranged far above the gas distributing plate 4, the heat-resistantparticles existing between the inlet 5 and the gas distributing plate 4can no longer have the function of prolonging or uniformalizing theresidence time of metal carbide powders in the fluidizing bed 1 andinstead rather increases the pressure loss of the oxidizing gasunnecessarily.

The inlet 5 for charging the metal carbide powders is associated with adevice for delivering the metal carbide powders. For example, it can beconnected with a constant powder delivery device 9 through a duct 10.For the constant powder delivery device 9, a device is advantageouslyused that can continuously deliver the metal carbide powders at aconstant rate or ratio, such as a rotary valve, table feeder, vibratingfeeder or the like. Metal carbide powders delivered from the constantpowder delivery device 9 are transported through the duct 10 by means ofair and charged in the fluidizing bed 1.

The outlet 6 from which the burned metal carbide powders and thecombustion gas are discharged must be arranged above the fluidizingbed 1. This is because the scattering of the metal carbide powders bythe combustion gas from the fluidizing bed 1 consisting of the fluidizedheat-resistant particles is important for separating the metal carbidepowders from the fluidizing bed 1. If the outlet means 6 is not arrangedabove the fluidizing bed 1, the scattering and separation of the metalcarbide powders from the fluidizing bed 1 consisting of the fluidizedheat-resistant particles becomes difficult. Preferably, the outlet 6 ispositioned sufficiently apart from the upper level surface of thefluidizing bed 1.

The metal carbide powders are discharged from the outlet 6 together withthe combustion gas, so that a separator 7 for recovering and collectingthe metal carbide powders has to be provided and connected to the outlet6 through a duct 11. As the separator or collector 7, use is generallymade of a device usually used for collecting fine powders. Particularly,a device having a high collection efficiency, such as an electric dustcollector, a Venturi scrubber, a filter type dust collector or the likeis preferable.

When burning and removing the free carbon contained in the metal carbidepowders by maintaining the fluidizing bed 1 at a desired temperature, ifthe quantity of the free carbon contained in the metal carbide powdersis relatively small, the desired temperature is difficult to maintain bythe thermal energy obtained by combustion of the free carbon alone, sothat an auxiliarly heating member 12, 13 or 14 for supplying anadditional heat to the fluidizing bed 1 is preferably arranged in theapparatus of the present invention. As the auxiliary heating member forheating the fluidizing bed 1, use may be made of a heat exchanger 12 forrecovering a sensible heat of the combustion gas and for preheating theoxidizing gas, an electric resistive heat generator 13, as shown in FIG.1, a burner 14 for burning a liquid fuel such as light oil, heavy oil,etc., or a gaseous fuel such as propane, natural gas, city gas, etc., asshown in FIG. 2 and the like means. For measuring the temperature of thefluidizing bed 1, there is incorporated in the fluidizing bed 1 atemperature measuring element 15 such as a thermocouple.

In operating the apparatus of the present invention, metal carbidepowder containing free carbon, delivered by the constant materialdelivery device 9, is transferred by a pneumatic conveyor and chargedfrom the inlet 5 into the fluidizing bed 1 near the gas dispersing plate4. During the rise of the powder in the fluidizing bed 1 consisting ofthe fluidized heat-resistant particles, the free carbon containedtherein is burned and removed. The residence time of metal carbidepowder in the fluidizing bed is controlled by adjusting the bed heightand the superficial velocity of the oxidizing gas. The reactiontemperature is maintained in the determined range, for example, by usingat least one of various types of the auxiliary heating members 12, 13and 14. As a result, burned or refined metal carbide powder is floatedin the fluidizing bed 1 consisting of the fluidized heat-resistantparticles and scattered and separated from the fluidizing bed 1. It issubsequently discharged together with the combustion gas from the outlet6 arranged above the fluidizing bed 1, and then recovered by theseparator 7.

Hereinafter, the present invention will be explained in more detail withreference to preferred Examples which, however, should not be construedin any means as limitations of the present invention.

In the Examples, all percentages shown are by weight basis unlessotherwise specified.

EXAMPLE 1

A fluidizing bed is formed by using air as the oxidizing gas at asuperficial gas velocity of 20 cm/sec and silica particles havingparticle diameters of 177-250μ as heat-resistant particles, while fixingthe bed height at minimum fluidizing gas velocity of 1.0 m of thefluidizing bed. Silicon carbide powders containing 19.4% of free carbonand having an average grain size of 83μ are charged at a rate of 20 gper minute and the refining reaction is operated continuously at areaction temperature of 950° C. The apparatus used is the same as shownin FIG. 1, having an electric heater for heating the fluidizing bedaround its exterior wall. The inner diameter of the sealed vessel is 0.2m and the height from the gas distributor to the outlet is 2.0 m.

Silicon carbide powders recovered in a bag filter contains 0.21% of freecarbon and loss of silicon carbide powders due to oxidation is 0.8%.Incorporation of silica particles into the silicon carbide is to anundetectable extent. A portion of the heat-resistant particles removedas a sample for analysis after a continuous operation of 2 hours showsthat no silicon carbide powder remains in the fluidizing bed consistingof the heat-resistant particles.

EXAMPLE 2 AND COMPARATIVE EXAMPLE 1

The operation of Example 1 is repeated using the same material andapparatus as those of Example 1, except that the reaction temperaturesare varied. The results are shown in the following Table 1.

                  TABLE 1                                                         ______________________________________                                                                     Loss of silicon                                           Reaction Free carbon                                                                              carbide due to                                            temperature                                                                            in product oxidation                                                 (°C.)                                                                           (%)        (%)                                              ______________________________________                                        Examples 1     950        0.21     0.8                                                 2-1   850        0.66     0.2                                                 2-2   1050       0.08     1.4                                        Comparative                                                                            1-1   700        4.21     0.1                                        Examples 1-2   1200       0.05     5.6                                        ______________________________________                                    

As seen from the above Table 1, free carbon can be burned and removedstably and efficiently for a long period of time in the Examples 1 and 2according to the present invention. On the contrary, when operated at alow reaction temperature as shown in the comparative Example 1--1, theproduct still contains a lot of free carbon owing to discharge andincorporation of unreacted free carbon into the product. While, whenoperated at a high reaction temperature as shown in the comparativeExample 1-2, free carbon remaining in the product can be decreased,whereas oxidation speed of silicon carbide powders increases remarkably,so that the loss of silicon carbide powders increases due to oxidation.

COMPARATIVE EXAMPLE 2

A heater built-in type rotary furnace having an inner diameter size of0.5 m, a length of 0.6 m and a heating member consisting ofelectric-resistive heating rods at its central portion is heated to atemperature of 750° C. while rotating at a rate of 1 rpm. 10 kg of thematerial used in Example 1 is charged in the rotary furnace to burn freecarbon contained therein while supplying air at a rate of 400 l/min.

Silicon carbide powders after burning of 7 hours contain 1.4% of freecarbon and loss of silicon carbide powders due to oxidation is 2.5%.Besides, it is found out that some silicon carbide powders aregranulated and free carbon is contained or incorporated in the granules.

As mentioned above, a rotary furnace cannot remove free carbonefficiently, so that it is not suited for a practical purpose.

COMPARATIVE EXAMPLE 3

120 g of the material same as that used in Example 1 is charged in afluidizing bed having a crosssectional area of 50 cm² and a height of 50cm in a sealed vessel of a structure as shown in FIG. 3, and heated to atemperature of 850° C. and fluidized by using air as an oxidizing gas ata superficial gas velocity of 5 cm/sec. The refining process is operatedwhile charging the material at a rate of 3 g/sec using a rotary feeder.The average residence time of the material in the container isapproximately 40 min.

Recovered silicon carbide powders contain 5.21% of free carbon and aloss of silicon carbide due to oxidation is 4.1%.

In the run of the Comparative Example 3, it is observed that after awhile from initiation of the fluidization, some of the silicon carbidepowders have been agglomerated at several portions of the fluidizing bedwhereby a strong deflection of flow has been formed. Meanwhile, it isfound out that, if the superficial gas velocity is so increased as tosolve the above deflection of flow, a large amount of fine particles arescattered and discharged from the gas discharge outlet arranged at theupper portion of the sealed vessel. Thus, it is extremely difficult toremove free carbon by a mere fluidization of silicon carbide powders.

EXAMPLE 3

In an apparatus having the same structure as shown in FIG. 2 accordingto the invention comprising a sealed vessel having an inner diameter of1.2 m and a height of 2.5 m from the gas distributor to the outlet, afluidizing bed is produced by using silica particles having diameters of177-250μ as heat-resistant particles and air as an oxidizing gas forfluidization at a superficial gas velocity of 25 cm/sec, while fixing abed height at minimum fluidizing gas velocity of 1.4 m of the fluidizingbed. In the fluidizing bed is charged the same material as that used inExample 1 at a rate of 0.6 kg/min, and the refining operation isconducted for a long period of time at a reaction temperature of 900° C.The reaction temperature is maintained by burning a light oil from aburner.

Silicon carbide powders collected by a bag filter contain 0.26-0.32% offree carbon and loss of silicon carbide due to oxidation is 0.7-0.9%.Silicon carbide powders of highly refined quality can be stably obtainedin a great quantity.

EXAMPLE 4

Titanium carbide powders containing 4.3% of free carbon and having anaverage grain size of 68μ are charged at a rate of 30 g/min into afluidizing bed produced by fluidizing heat-resistant alumina particleshaving particle diameters of 177-250μ by means of air as an oxidizinggas for fluidization at a superficial gas velocity of 30 cm/sec, and therefining operation is performed continuously at a reaction temperatureof 900° C. The apparatus used is the same as that used in Example 1.

Titanium carbide powders recovered by a bag filter contain 0.12% of freecarbon and loss of titanium carbide due to oxidation is 1.2%.Incorporation of alumina particles in titanium carbide powders andtitanium carbide powders remaining in the fluidization bed are both toundetectable extents.

As apparent from the above explanation, according to the refining methodand apparatus of the present invention, free carbon contained in varioustypes of metal carbides which heretofore has been difficult to refine isburned and removed extremely efficiently without causing oxidation ofmetal carbide powders, so that loss of metal carbide powders due tooxidation can substantially be obviated. Moreover, metal carbide powderscan be treated in a great quantity in an industrial scale and producedat high quality, so that the present invention is exceedingly usefulindustrially.

Although the present invention has been explained with reference tospecific values and embodiments, it will of course be apparent to thoseskilled in the art that the present invention is not limited thereto andmany variations and modifications are possible without departing fromthe broad aspect and scope of the present invention as defined in theappended claims.

What is claimed is:
 1. An apparatus for refining metal carbide powders containing free carbon and having an average grain size of not more than 200 microns without substantial oxidation of the metal carbides, comprising a sealed vessel containing a fluidizing bed with a bed height at minimum fluidizing gas velocity within a range of 0.2-3.0 m consisting of heat-resistant particles having an average particle diameter of 150-500μ fluidized by an oxidizing gas, an inlet for introducing the oxidizing gas arranged at the lower end of the sealed vessel, a gas distributor which is a plate of porous heat-resistant and oxidation-resistant material having uniformly spaced small holes each having a diameter of not more than 5 mm and an opening ratio of cross-sectional area of the small holes to cross-sectional area of the sealed vessel within a range of 0.1-10% for dispersing the oxidizing gas in the fluidizing bed arranged at a lower part of the fluidizing bed, an inlet for charging the metal carbide powders which discharges substantially upwardly in immediate proximity to the gas distributor and is so arranged as to ensure generally even distribution of the metal carbide powders in the fluidizing bed, a heating member for heating the fluidizing bed arranged in the refining apparatus to a temperature of 800°-1100° C. to burn and remove the free carbon from the metal carbide powders, an outlet for discharging a mixture of refined metal carbide powders and combustion gas from the fluidizing bed arranged above the fluidizing bed, and a separator for recovering the refined metal carbide powders from the mixture discharged from the outlet.
 2. An apparatus as defined in claim 1, wherein a bubbles-dispersing element for improving efficiency of contacting the free carbon with the oxidizing gas in the fluidizing bed is arranged in the fluidizing bed. 